Attachment structure of lighting device

ABSTRACT

An attachment structure of a lighting device has: a holder provided on a top surface of a door pocket that constitutes a door lining, the lighting device being placed in the holder; walls for fixing the lighting device placed in the holder; a light source supporting part; and a connector supporting part. In this case, the attachment structure and the top surface of the door pocket are configured integrally.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of prior U.S. patentapplication Ser. No. 14/382,940, filed Sep. 4, 2014, which is the USNational Phase of International Application PCT/JP2013/053625 filed Feb.15, 2013, which is based on Japanese Patent Application Nos. 2012-051565and 2012-051564, both filed Mar. 8, 2012. The entire disclosures ofthese priority applications are incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to an attachment structure for a lightingdevice, and more particularly to an attachment structure suitable forinstalling a lighting device on an interior member of a vehicle thatserves as an attachment target on which the lighting device is to beinstalled.

BACKGROUND ART

Lighting devices for use in vehicles are installed on an interior memberof a vehicle as follows: After a lighting device has been fixed to anattachment structure, the attachment structure is placed to engage inholes, etc. defined in the interior member of the vehicle. JapanesePatent No. 3840862 discloses that an LED (Light-Emitting Diode) lightsource as a lighting device is fixed to a casing that serves as anattachment structure, and the feet of the casing are placed to engage inholes defined in an inside handle bezel, so that the LED light sourceand the casing are installed on the inside handle bezel that serves asan attachment target.

A lighting device for use in vehicles is installed on an interior memberof a vehicle by teeth on a light source of the lighting device whichengage in holes, etc. defined in the interior member of the vehicle.Japanese Laid-Open Patent Publication No. 2009-245681 discloses alighting device including an LED lamp serving as a light source and aconnector for supplying electric power to the LED lamp, the light sourcehaving teeth on side surfaces thereof.

SUMMARY OF INVENTION

According to the technology disclosed in Japanese Patent No. 3840862,however, since the casing and the inside handle bezel are not integralwith each other, the number of parts used is large. The number ofman-hours for assembling the lighting device is also large because theassembling process requires the step of attaching the LED light sourceto the casing and the step of assembling the case with the LED lightsource attached thereto on the inside handle bezel.

A connector is connected to a wire harness in a vehicle so that theconnector can be supplied with electric power from a battery or thelike. Therefore, the connector tends to be subjected to vibrations andloads from the wire harness. According to the technology disclosed inJapanese Laid-Open Patent Publication No. 2009-245681, however, as anattachment structure is not designed to support the connector, thelighting device that includes the connector cannot stably be supportedwhen the connector is subjected to vibrations and loads from the wireharness.

It is a first object of the present invention to provide an attachmentstructure which is of a simple structure capable of installing alighting device on an attachment target.

A second object of the present invention is to provide an attachmentstructure that is capable of stably supporting a lighting device thatincludes a connector.

In order to achieve the first object, there is provided in accordancewith the present invention an attachment structure for installing alighting device on an attachment target, comprising a rest disposed on asurface of the attachment target and configured to place the lightingdevice thereon, and a mounting member configured to fix the lightingdevice placed on the rest, wherein the attachment structure is integralwith the attachment target (first feature).

The rest should preferably be arranged as an attachment angle changerconfigured to adjust an attachment angle at which the lighting device isinstalled on the attachment target (second feature).

Specifically, the rest should preferably be arranged as a heightadjuster configured to keep a placement surface of the rest for thelighting device substantially horizontal by adjusting a height of therest depending on a state of the surface of the attachment target (thirdfeature).

The height adjuster may comprise a plurality of ribs rising from thesurface of the attachment target (fourth feature).

The mounting member should preferably have an engaging member configuredto engage the lighting device, and at least one of the ribs shouldpreferably be joined to the mounting member (fifth feature).

When the lighting device is placed on the rest so that an attachmentsurface of the lighting device faces a placement surface of the rest,the lighting device should preferably have side surfaces extending fromthe attachment surface so as to be spaced from the placement surface,and when the mounting member faces one of the side surfaces of thelighting device, an opening should preferably be defined in a locationwhich faces the mounting member and which faces another of the sidesurfaces of the lighting device (sixth feature).

The engaging member should preferably comprise a hook configured toengage one of the side surfaces of the lighting device and a surface,which is opposite to the attachment surface, of the lighting device(seventh feature).

In order to achieve the second object, there is also provided inaccordance with the present invention an attachment structure forinstalling a lighting device on an attachment target, wherein thelighting device comprises a light source unit configured to outputillumination light and a connector configured to supply electric powerto the light source unit, and the attachment structure has at least aconnector support configured to install and support the connector on theattachment target (eighth feature).

The attachment structure should preferably further include a lightsource support configured to install and support the light source uniton the attachment target (ninth feature).

When the lighting device is placed on the attachment target so that anattachment surface of the lighting device faces a surface of theattachment target, the lighting device has side surfaces extending fromthe attachment surface so as to be spaced from the surface of theattachment target, the light source support supports a side surface ofthe light source unit that makes up part of one of the side surfaces ofthe lighting device, and the connector support supports a side surfaceof the connector which makes up part of one of the side surfaces of thelighting device (tenth feature).

The light source unit and the connector of the lighting device shouldpreferably be joined along the surface of the attachment target, and atleast a portion of the connector on one of the side surfaces of thelighting device should preferably be supported by the connector support,and a portion of the light source unit on another one of the sidesurfaces of the lighting device should preferably be supported by thelight source support (eleventh feature).

The attachment structure should preferably further include a positionlimiter configured to limit displacement of the lighting device in adirection along the surface of the attachment target (twelfth feature).

The position limiter may comprise a wall held in contact with the sidesurface of the lighting device and/or a portion of the connector supportand a portion of the light source support (thirteenth feature).

The position limiter should preferably be integrally formed with thelight source support and the connector support (fourteenth feature).

When the connector support or the light source support faces one of theside surfaces of the lighting device, an opening should preferably bedefined in a location which faces the connector support or the lightsource support and which faces another of the side surfaces of thelighting device (fifteenth feature).

The attachment structure should preferably further include anillumination hole configured to pass therethrough the illumination lightoutput from the light source unit, and the opening and the illuminationhole should preferably be disposed in respective positions which arespaced from each other (sixteenth feature).

The attachment target should preferably comprise an interior member of avehicle, and the illumination hole should preferably be of a shape thatis elongate along a longitudinal direction of the lighting device, andbe positionally displaced from the light source unit outwardly of apassenger compartment of the vehicle (seventeenth feature).

At least one of the connector support and the light source supportshould preferably have an engaging member configured to engage thelighting device (eighteenth feature).

The engaging member of the connector support comprises a hook configuredto engage a side surface of the connector and a surface, which isopposite to the attachment surface, of the connector, and the engagingmember of the light source support comprises an engaging hole configuredto engage a ledge on a side surface of the light source unit or a recessconfigured to house the ledge therein (nineteenth feature).

The attachment target comprises an interior member of a vehicle, and theengaging hole is positioned outwardly of the passenger compartment inthe attachment structure (twentieth feature).

Another rib supporting the mounting member or the position limitershould preferably be joined to the mounting member or the positionlimiter (twenty-first feature).

An upper component may be mounted on the attachment target by an uppercomponent mount above the lighting device and the attachment structurein the attachment target, and the lighting device and the attachmentstructure, and the upper component mount may be staggered in mutuallydifferent positions along longitudinal directions of the attachmenttarget and disposed on the attachment target (twenty-second feature).

According to the first feature of the invention, since the attachmentstructure and the attachment target are integral with each other, theprocess of installing the lighting device on the attachment target iscompleted by placing the lighting device on the rest of the attachmentstructure and supporting and fixing the lighting device with themounting member. As a result, the number of parts used and the number ofman-hours for installing the lighting device are reduced compared withthe technology disclosed in Japanese Patent No. 3840862, making itpossible to install the lighting device on the attachment target with asimpler arrangement. The rigidity of the attachment structure isincreased as the attachment structure and the attachment target areintegral with each other.

According to the second feature of the invention, the rest functions asan attachment angle changer for adjusting an attachment angle at whichthe lighting device is installed on the attachment target. By adjustingthe attachment angle, it is possible to set the illumination angle ofthe illumination light output from the lighting device to a desiredangle.

According to the third feature of the invention, the rest functions as aheight adjuster for keeping a placement surface for the lighting devicesubstantially horizontal. The attachment angle at which the lightingdevice is installed on the attachment target can easily be changed byadjusting the height of the rest depending on the state of the surfaceof the attachment target. As a result, while the illumination angle ofthe illumination light output from the lighting device is set to adesired angle, it is possible to install the lighting device on the restwhile the placement surface is kept substantially horizontal.

According to the fourth feature of the invention, the height adjustercomprises a plurality of ribs rising from the surface of the attachmenttarget. As the ribs are integral with the attachment target, the numberof parts used is reduced, and at the same time the rigidity of theattachment structure is increased.

According to the fifth feature of the invention, at least one of theribs is joined to the mounting member. The rigidity of the mountingmember can be increased while the illumination angle of the illuminationlight output from the lighting device is set to a desired angle. Anengaging member on the mounting member engages the lighting device,thereby stably supporting the lighting device.

According to the sixth feature of the invention, an opening is definedin facing relation to the mounting member. When the attachment structureis molded using a die assembly, at least a portion of the attachmentstructure which is lower than the engaging member may be molded by alower die, whereas a portion of the attachment structure which is higherthan the lower end may be molded by an upper die. Preferably, the lowerdie has an extension extending through the opening to the mountingmember. After the attachment structure is molded using the die assembly,the lower die is slid in the direction from the mounting member towardthe opening. Therefore, the lower die can easily be removed. When theupper die is removed upwardly, the attachment structure molded todesired shape is obtained.

According to the seventh feature of the invention, as the hook engagesthe lighting device, greater rigidity is achieved than if the hookengages in a hole. The lighting device can thus be stably supported.

According to the eighth feature of the invention, when the lightingdevice is installed on the attachment target by the attachmentstructure, the connector of the lighting device is supported by theconnector support. Therefore, even if vibrations and loads are appliedfrom a wire harness to the connector, the connector is stably supported.The lighting device that includes the connector is thus stablysupported.

According to the ninth feature of the invention, the light source unitis supported by the light source support, and the connector is supportedby the connector support. The lighting device is thus stably supported.

According to the tenth feature of the invention, the light sourcesupport supports a side surface of the light source unit and theconnector support supports a side surface of the connector. The lightingdevice is thus stably supported.

According to the eleventh feature of the invention, at least one of theside surfaces of the lighting device is supported by the connectorsupport, and another one of the side surfaces of the lighting device issupported by the light source support. The two supports support the twoside surfaces, respectively, of the lighting device in facing relationto each other. As a consequence, the lighting device is easily andstably supported.

According to the twelfth feature of the invention, the lighting deviceis prevented from being displaced in a direction along the surface ofthe attachment target, i.e., in the lateral directions thereof. As aconsequence, the lighting device is stably supported.

According to the thirteenth feature of the invention, a wall held incontact with the side surfaces of the lighting device and/or portions ofthe connector support and the light source support serve as the positionlimiter. The position limiter is thus easily capable of limiting theposition of the lighting device.

According to the fourteenth feature of the invention, the positionlimiter, the light source support, and the connector support areintegrally formed with each other. Therefore, the position limiter, thelight source support, and the connector support are of increasedrigidity, making it possible to support the lighting device stably.

According to the fifteenth feature of the invention, an opening isdefined in facing relation to the connector support or the light sourcesupport. If the connector support or the light source support has anengaging member for engaging the light source, then when the attachmentstructure is molded using a die assembly, at least a portion of theattachment structure which is lower than the lower end of the engagingmember may be molded by a lower die, whereas a portion of the attachmentstructure which is higher than the lower end may be molded by an upperdie. Preferably, the lower die has an extension extending through theopening to the connector support or the light source support. After theattachment structure is molded using the die assembly, the lower die isslid in the direction from the connector support or the light sourcesupport toward the opening. Therefore, the lower die can easily beremoved. When the upper die is removed upwardly, the attachmentstructure molded to desired shape is obtained.

According to the sixteenth feature of the invention, the opening and theillumination hole are positionally displaced from each other, therebypreventing the attachment structure from being reduced in rigidity atone location due to the opening.

According to the seventeenth feature of the invention, the illuminationhole is defined in the outward direction of the vehicle, i.e., in thedirection away from the occupants of the vehicle, so that the length ofthe illumination hole along the longitudinal directions of the lightingdevice can be increased in the outward direction of the vehicle awayfrom the occupants of the vehicle.

According to the eighteenth feature of the invention, at least one ofthe connector support and the light source support has an engagingmember. The engaging member and the lighting device can be held inengagement with each other while the lighting device is supported. As aresult, the lighting device is stably supported.

According to the nineteenth feature of the invention, the hook engagesthe connector which tends to be subjected to vibrations and loads fromthe wire harness. Therefore, the connector is stably supported withgreater rigidity than if the hook engages in a hole. The ledge of thelight source unit which is less liable to be subjected to vibrations andloads from the wire harness engages in the engaging hole or and therecess, thereby stably supporting the light source unit.

According to the twentieth feature of the invention, the engaging holeis positioned outwardly of the passenger compartment in the attachmentstructure. When the lighting device is to be installed on an interiormember before the interior member is mounted in the vehicle, theengaging hole is positioned at a location that can easily be visuallyrecognized by the worker. The worker is thus capable of easilyconfirming whether the ledge of the light source unit is engaging in theengaging hole or not.

According to the twenty-first feature of the invention, another rib isjoined to the mounting member or the position limiter and supports themounting member or the position limiter. The rigidity of the attachmentstructure is thus increased.

According to the twenty-second feature of the invention, the lightingdevice and the attachment structure, and an upper component mount arestaggered in mutually different positions along the longitudinaldirections of the attachment target and disposed on the attachmenttarget. When the upper component is removed from the attachment target,the lighting device and the attachment structure are prevented fromgetting in the way.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a door lining that incorporates anattachment structure for a lighting device according to an embodiment ofthe present invention;

FIG. 2 is a perspective view of a back surface of the door lining shownin FIG. 1;

FIG. 3 is a perspective view showing at an enlarged scale an uppersurface side of a door pocket shown in FIG. 2;

FIG. 4 is a perspective view showing the manner in which a lightingdevice is installed on the attachment structure according to the presentembodiment;

FIG. 5 is a perspective view of the assembly of the attachment structureshown in FIG. 4 and the lighting device installed thereon;

FIG. 6 is a plan view of the assembly shown in FIG. 5;

FIG. 7 is a plan view showing the attachment structure shown in FIG. 4;

FIG. 8 is a cross-sectional view taken along line VIII-VIII of FIG. 6;

FIG. 9 is a schematic plan view of a die assembly that is used tomanufacture the attachment structure shown in FIG. 4; and

FIG. 10 is a schematic front view of the die assembly shown in FIG. 9.

DESCRIPTION OF EMBODIMENTS

An attachment structure for a lighting device according to a preferredembodiment of the present invention will be described in detail belowwith reference to the accompanying drawings.

An attachment structure 12 for a lighting device 10 according to thepresent embodiment is applied to a door lining (door trim) 14 which isto be attached to an inner side (facing the passenger compartment) of adoor panel of a vehicle as shown in FIGS. 1 and 2, for example. However,the attachment structure 12 according to the present embodiment is notlimited to the embodiment, but may be used to install the lightingdevice 10 on an attachment target such as an interior member of thevehicle other than the door lining 14 or an object other than theinterior member. In the description that follows, the lighting device 10is installed on the door lining 14 by the attachment structure 12.

A door arm rest (upper component) 16 that extends along the longitudinaldirections (the directions indicated by the arrow A) of the vehicle isdisposed in a central region of the door lining 14 which may be made ofplastics or the like. The door lining 14 has in its lower region a lowermember 17 including a door pocket 18 for accommodating articles thereinand a speaker housing 20 for housing a speaker. The door pocket 18 ismade partly concave to provide a cavity 22 for accommodating articlestherein.

On a reverse side (outside of the passenger compartment) of the doorlining 14 shown in FIG. 2, the lighting device 10 is installed by theattachment structure 12 on an upper surface 24 of the door pocket 18that defines the cavity 22. The upper surface 24 has an illuminationhole 26 (see FIG. 1) defined therein in alignment with the lightingdevice 10. The lighting device 10 emits illumination light 28 into thecavity 22 through the illumination hole 26.

As shown in FIGS. 2 and 3, the lower member 17 has on its upper end aplurality of mounts (upper component mounts) 32 having respective mountholes 30 on the reverse side of the door lining 14. The lower member 17is mounted on the door arm rest 16 by the mounts 32 that engage aplurality of teeth 34 on a lower end of the door arm rest 16. The mounts32, the lighting device 10, and the attachment structure 12 are disposedin positions that are shifted along the directions indicated by thearrow A. As a result, the lighting device 10 and the attachmentstructure 12 do not lie in the way when the lower member 17 is installedon and detached from the door arm rest 16. Structural details of thedoor lining 14 other than the door arm rest 16 and the door pocket 18are essentially the same as the structural details of known doorlinings, and will not be described in detail below.

The lighting device 10 and the attachment structure 12 will be describedin greater detail below with reference to FIGS. 4 through 8.

The lighting device 10 has a substantially rectangular casing 40, andcomprises a light source unit 44 having a light source 42 for emittingillumination light 28 and a connector 48 coupled to the light sourceunit 44 and adapted to be connected to a wire harness 46 in the vehicle.The rectangular casing 40 comprises a comparatively small first block 40a on one end portion and a comparatively large second block 40 b on theother end portion. The light source unit 44 is provided in the firstblock 40 a, and the connector 48 is provided in the second block 40 b.

According to the present embodiment, the lighting device 10 is installedon the upper surface 24 of the door pocket 18 by the attachmentstructure 12 with the first block 40 a being oriented in the directionindicated by the arrow A1, which indicates the forward side of thevehicle, and the second block 40 b being oriented in the directionindicated by the arrow A2, which indicates the rearward side of thevehicle.

The light source 42 may comprise a known LED or organic EL(ElectroLuminescence) light source. The connector 48 has a connectionterminal 50 for connection to the wire harness 46, and can energize thelight source 42 when supplied with electric power from a battery, notshown, on the vehicle through the wire harness 46.

The casing 40 has a bottom surface 52 as an attachment surface to bemounted on the upper surface 24 of the door pocket 18, four sidesurfaces 54 through 60 extending upwardly from the bottom surface 52,and an upper surface 62 opposite to the bottom surface 52. The bottomsurface 52 lies substantially flatwise. The side surfaces 54, 56 liesubstantially perpendicularly to the directions indicated by the arrowB, which indicates transverse directions of the vehicle. The sidesurface 54 faces in the direction indicated by the arrow B1 which isoriented toward the passenger compartment, whereas the side surface 56faces in the direction indicated by the arrow B2 which is oriented awayfrom the passenger compartment. The side surface 58 faces in thedirection indicated by the arrow A1, whereas the side surface 60 facesin the direction indicated by the arrow A2.

As described above, the first block 40 a and the second block 40 b areof different sizes, and the bottom surface 52 of the casing 40 liessubstantially flatwise. The second block 40 b bulges in the upwarddirection indicated by the arrow C1 and in the transverse directionsindicated by the arrow B, compared with the first block 40 a. The sidesurface 54 is made up of a side surface 54 a of the first block 40 a anda side surface 54 b of the second block 40 b. The side surface 56 ismade up of a side surface 56 a of the first block 40 a and a sidesurface 56 b of the second block 40 b. The upper surface 62 is made upof an upper surface 62 a of the first block 40 a and an upper surface 62b of the second block 40 b.

The first block 40 a, which includes the light source unit 44, has twobar-shaped ridges 63 extending from the side surface 58 in the directionindicated by the arrow A1, a ledge 64 extending from the side surface 54a in the direction indicated by the arrow B1, and a ledge 66 extendingfrom the side surface 56 a in the direction indicated by the arrow B2,the ledge 66 being identical in shape to the ledge 64.

The second block 40 b, which includes the connector 48, has a bar-shapedridge 68 extending from a portion of the side surface 54 b near thefirst block 40 a in the direction indicated by the arrow B1, and abar-shaped ridge 70 extending from a portion of the side surface 56 bnear the first block 40 a in the direction indicated by the arrow B2,the ridge 70 being identical in shape to the ridge 68.

For use with the lighting device 10 thus constructed, the attachmentstructure 12 according to the present embodiment is molded of a resinintegrally with the upper surface 24 of the door pocket 18 by a dieassembly 120 (see FIGS. 9 and 10) to be described later, for example.

As described above, since the light source 42 is required to emitillumination light 28 through the illumination hole 26 into the cavity22 of the door pocket 18, the attachment structure 12 is disposed insurrounding relation to the illumination hole 26 in the upper surface24.

Specifically, the attachment structure 12 has a rest 80 for placing thebottom surface 52 of the lighting device 10 thereon. The rest 80comprises a plurality of ribs 82 standing upwardly from the uppersurface 24 in the direction indicated by the arrow C1.

As shown in FIGS. 2, 3, and 8, the upper surface 24 is of a curved shapethat is inclined downwardly along the direction indicated by the arrowA2.

According to the present embodiment, in order to install the lightingdevice 10 at a desired attachment angle on the upper surface 24, theheights of the ribs 82 are adjusted depending on the shape of the uppersurface 24 thereby to keep the respective upper ends of the ribs 82lying substantially flush with each other. In this manner, the rest 80has a substantially flat placement surface for the lighting device 10.As the placement surface is made flat by adjusting the heights of theribs 82, the lighting device 10 can be placed on the rest 80, and theangle at which the lighting device 10 is installed on the upper surface24 can be adjusted to a desired angle.

FIGS. 3 and 8 illustrate that the respective upper ends of the ribs 82are adjusted to the same height along the horizontal directionsindicated by the arrow A, keeping the placement surface of the rest 80substantially horizontal. According to the present embodiment, asdescribed above, the respective upper ends of the ribs 82 are adjustedto adjust the placement surface to a desired attachment angle. Therespective upper ends of the ribs 82 may be adjusted to incline theplacement surface at a certain angle to the directions indicated by thearrow A, for example.

As shown in plan in FIG. 7, the ribs 82 extend along the directionsindicated by the arrow B around the illumination hole 26, which is of asubstantially rectangular shape, extending along the directionsindicated by the arrow A. Those ribs 82 that are positioned in thedirection indicated by the arrow A2 away from the illumination hole 26are comparatively long, whereas those ribs 82 that are positioned in thedirection indicated by the arrow A1 adjacently to the illumination hole26 are comparatively short.

The ribs 82 are surrounded by various mounting members that support theside surfaces 54 through 60 of the casing 40, thereby securing thelighting device 10 placed on the rest 80. These mounting members riseupwardly from the upper surface 24 along the direction indicated by thearrow C1, are integral with the upper surface 24, and can be joined tothe ribs 82.

Specifically, a substantially L-shaped wall 90 that supports the sidesurfaces 54 a, 58 and a wall-like light source support 92 that supportsthe side surface 56 a rise from the upper surface 24 as mounting membersfor the first block 40 a. A side of the wall 90 that projects in thedirection indicated by the arrow B2 and a side of the light sourcesupport 92 that projects in the direction indicated by the arrow A1 arejoined to each other. The light source support 92 has a hole 94 definedtherein for engaging the ledge 66. The wall 90 has a recess 96 that isconcave in the direction indicated by the arrow B1 for accommodating theledge 64 therein.

The comparatively short ribs 82 that are positioned adjacently to theillumination hole 26 are joined to the wall 90 in the directionindicated by the arrow B1. Also, the comparatively short ribs 82 thatare positioned adjacently to the illumination hole 26 and thecomparatively long ribs 82 that are positioned away from theillumination hole 26 are joined to the light source support 92. Thelight source support 92 is supported by other ribs 98 that extend in thedirection indicated by the arrow B2.

A portion of the wall 90, a wall-like connector support 100 joined tothe wall 90 and supporting the side surface 54 b, and a wall 102 thatsupports a portion of the side surface 56 b rise from the upper surface24 as mounting members for the second block 40 b.

On an upper end of the connector support 100, a hook 104 is provided sothat the hook 104 engages the side surface 54 b and the upper surface 62b of the second block 40 b. The comparatively long ribs 82 that arepositioned away from the illumination hole 26 are joined to theconnector support 100. The connector support 100 is supported by otherribs 105 that extend in the direction indicated by the arrow B1. One ofthe comparatively long ribs 82 that are positioned away from theillumination hole 26 is joined to the wall 102, which is supported byanother rib 106 that extends in the direction indicated by the arrow B2.

A region between the light source support 92 and the wall 102 in theattachment structure 12 is defined as an opening 107 that faces theconnector support 100 and the hook 104 and that also faces the sidesurface 56 b of the second block 40 b. The illumination hole 26, thehole 94, and the opening 107 are disposed in positions that are spacedfrom each other in order to avoid a reduction in the rigidity of theattachment structure 12. As shown in FIGS. 5 through 7, the light sourcesupport 92 and the connector support 100 are disposed in obliquelyfacing relation to each other. Specifically, the connector support 100supports the side surface 54 b of the second block 40 b that makes uppart of the side surface 54 of the lighting device 10, and the lightsource support 92 supports the side surface 56 a of the first block 40 athat makes up part of the other side surface 56 of the lighting device10.

A process of installing the lighting device 10 on the upper surface 24of the door pocket 18 using the attachment structure 12 thus constructedwill be described below.

First, the lighting device 10 is lowered along the direction indicatedby the arrow C2 while the lighting device 10 is being positionedinwardly of the walls 90, 102, the light source support 92, and theconnector support 100 as viewed in plan. The corner of the second block40 b that is provided by the bottom surface 52 and the side surface 54 bis brought into abutment against the hook 104.

When the lighting device 10 is further lowered, the connector support100 and the hook 104 are integrally buckled by the pressing force fromthe corner about the proximal end of the connector support 100 (theportion of the connector support 100 on the upper surface 24) in thedirection indicated by the arrow B1.

Upon further descent of the lighting device 10, the side surface 54 a ofthe first block 40 a is brought into contact with the wall 90, and theside surface 58 thereof is also brought into contact with the wall 90through the ridges 63. Also, the side surface 56 a is brought intocontact with the light source support 92. The side surface 54 b of thesecond block 40 b is brought into contact with the connector support100, and the side surface 56 b thereof is also brought into contact withthe wall 102. As a result, the lighting device 10 can slide (descend) inthe direction indicated by the arrow C2 along the wall surfaces of thewalls 90, 102, the light source support 92, and the connector support100.

When the bottom surface 52 of the casing 40 contacts the upper ends ofthe ribs 82, the lighting device 10 is placed on the placement surfaceof the rest 80, and the light source 42 and the illumination hole 26face each other. Since the upper surface 62 b of the second block 40 bis in a lower position than a lower end 108 of the hook 104, theconnector support 100 and the hook 104 are released from the pressurefrom the second block 40 b, and snaps back into the original position inwhich they were before being pressed.

As a result, the hook 104 engages the side surface 54 b and the uppersurface 62 b of the second block 40 b, and cooperate with the connectorsupport 100 and the wall 102 in fixing the second block 40 b (connector48) in place. The ledge 66 of the first block 40 a engages in the hole94 of the light source support 92 and the ledge 64 thereof isaccommodated in the recess 96 of the wall 90, so that the light sourcesupport 92 cooperates with the wall 90 in fixing the first block 40 a(light source unit 44) in place.

The first block 40 a now has the side surface 54 a and the side surface58 supported by the wall 90 (the latter through the ridges 63), and theside surface 56 a supported by the light source support 92. The secondblock 40 b has the side surface 54 b supported by the wall 90 and theconnector support 100, the side surface 56 b supported by the wall 102,and the two bar-shaped ridges 68, 70 supported by the wall 90 and thelight source support 92. Consequently, the walls 90, 102, the lightsource support 92, and the connector support 100 also function asposition limiters for limiting displacement of the lighting device 10 inthe horizontal directions indicated by the arrow A and the horizontaldirections indicated by the arrow B.

When the lighting device 10 is installed on the upper surface 24 by theattachment structure 12, as shown in plan in FIG. 7, a center 110 of thelight source 42 (where the illumination light 28 is emitted) and acentral axis 112 of the illumination hole 26 along the directionsindicated by the arrow A are spaced from each other by a distance d. Inother words, the illumination hole 26 is offset from the light source 42by the distance d in an outward direction of the vehicle, i.e., in thedirection indicated by the arrow B2. Therefore, when the light source 42emits the illumination light 28 into the cavity 22 of the door pocket18, an area of the cavity 22 which is located more outwardly in theoutward direction of the vehicle is mainly illuminated. As aconsequence, the illumination light 28 is prevented from being radiatedinto the space in the passenger compartment outside of the cavity 22.

The illumination hole 26 is of a rectangular shape that is elongate inthe directions indicated by the arrow A, i.e., in the longitudinaldirections of the vehicle. Therefore, the cavity 22 is illuminated withthe illumination light 28 in the longitudinal directions of the vehicle.Even if the light source 42 is positionally displaced in the directionsindicated by the arrow A, the illumination light 28 is reliably emittedinto the cavity 22.

The lighting device 10 thus installed can be detached from the uppersurface 24 and the attachment structure 12 as follows:

The connector support 100 and the hook 104 are buckled in the directionindicated by the arrow B1 about the proximal end of the connectorsupport 100, thereby brining the hook 104 out of engagement with thesecond block 40 b. The upper end of the light source support 92 isbuckled in the direction indicated by the arrow B2 about the proximalend of the light source support 92, thereby bringing the ledge 66 out ofengagement with the hole 94. While the hook 104 and the ledge 66 arebeing thus disengaged, the lighting device 10 is lifted in the directionindicated by the arrow C1. The lighting device 10 is thus detached fromthe attachment structure 12.

FIGS. 9 and 10 schematically show the manner in which the attachmentstructure 12 according to the present embodiment is molded using the dieassembly 120.

The die assembly 120 comprises an upper die 122 and a lower die 124.

Since the attachment structure 12 according to the present embodiment isintegral with the upper surface 24 of the door pocket 18 as describedabove, the lower die 124 cannot slide in the direction indicated by thearrow C2 when the attachment structure 12 is molded. As the connectorsupport 100 has the hook 104, there is an undercut in a region below thehook 104, so that the connector support 100 cannot be molded by theupper die 122. Furthermore, the ribs 82, the walls 90, 102, the lightsource support 92, and the connector support 100 rise from the uppersurface 24, and the mounting members as the walls 90, 102, the lightsource support 92, and the connector support 100 are disposed insurrounding relation to the ribs 82. Consequently, the attachmentstructure 12 is complex in construction.

According to the present embodiment, as shown in FIGS. 9 and 10, theupper die 122 and the lower die 124 are constructed as follows: FIG. 9is a schematic plan view of the upper die 122 and the lower die 124 atthe height of the undercut referred to above, whereas FIG. 10 is aschematic front view of the upper die 122 and the lower die 124.

The lower die 124 is slidable along the upper surface 24 in thedirections indicated by the arrow B.

For molding the attachment structure 12, the lower die 124 is disposedin a position that is spaced from the position where the light sourcesupport 92 and the wall 102 are to be molded, in the direction indicatedby the arrow B2. As shown in FIG. 9, the lower die 124 has a portionconstructed as an extension 126 extending through the opening 107 intothe position where the connector support 100 is to be molded. Theextension 126 has a height that is set to the height of the lower end108 of the hook 104. Except for the extension 126, the height of thelower die 124 at the location of the attachment structure 12 isgenerally set to the heights of the light source support 92 and the wall102.

The lower die 124 is disposed as shown in FIGS. 9 and 10, and a resinthat is molten with heat is poured into the die assembly. Thereafter,the upper die 122 is lowered in the direction indicated by the arrow C2,molding the attachment structure 12 shown in FIGS. 4 through 8. Afterthe attachment structure 12 is molded, the upper die 122 is lifted inthe direction indicated by the arrow Cl, and the lower die 124 is slidin the direction indicated by the arrow B2.

With the attachment structure 12 for the lighting device 10 according tothe present embodiment, when the lighting device 10 is installed on theupper surface 24 of the door pocket 18 of the door lining 14 as anattachment target by the attachment structure 12, the connector 48 issupported by the connector support 100. Therefore, even if vibrationsand loads are applied from the wire harness 46 to the connector 48, theconnector 48 is stably supported. The lighting device 10 that includesthe connector 48 is thus stably supported.

The light source support 92 supports the light source unit 44 and theconnector support 100 supports the connector 48, thereby stablysupporting the lighting device 10. The light source support 92 supportsthe side surface 56 a of the first block 40 a that corresponds to thelight source unit 44, whereas the connector support 100 supports theside surface 54 b of the second block 40 b that corresponds to theconnector 48. In other words, the two supports support the two sidesurfaces 54, 56, respectively, of the lighting device 10 in facingrelation to each other. As a consequence, the lighting device 10 iseasily and stably supported.

According to the present embodiment, since the walls 90, 102, the lightsource support 92, and the connector support 100 support the sidesurfaces 54, 56, 58 of the lighting device 10, the lighting device 10 isprevented from being displaced in directions along the upper surface 24of the door pocket 18, i.e., in the lateral directions thereof (thedirections indicated by the arrow A and the directions indicated by thearrow B). As a consequence, the lighting device 10 mounted on theattachment structure 12 is positionally limited and stably supportedwith ease.

Inasmuch as the wall 90, the light source support 92, and the connectorsupport 100 are integrally formed with each other, these mountingmembers are of increased rigidity for stably supporting the lightingdevice 10. Specifically, as the wall 90 and the connector support 100are joined to each other along the directions indicated by the arrow A,whereas the wall 90 and the light source support 92 are joined to eachother along the directions indicated by the arrow A, the mountingmembers maintain their rigidity and the lighting device 10 is reliablypositionally limited.

The hook 104 on the connector support 100 engages the second block 40 b,the ledge 66 engages in the hole 94 of the light source support 92, andthe ledge 64 engages in the recess 96 of the wall 90, thereby stablysupporting the lighting device 10. In other words, since the hook 104engages the second block 40 b which tends to be subjected to vibrationsand loads from the wire harness 46, the connector 48 is stably supportedwith greater rigidity than if the hook 104 engages in a hole. The ledges64, 66 of the first block 40 a which are less liable to be subjected tovibrations and loads from the wire harness 46 engage in the hole 94 andthe recess 96, thereby stably supporting the light source unit 44.

Because the hole 94 faces in the direction indicated by the arrow B2outwardly of the passenger compartment, when the lighting device 10 isto be installed in the door pocket 18 before the door lining 14 ismounted on the door panel, the hole 94 is positioned at a location thatcan easily be visually recognized by the worker. The worker is thuscapable of easily confirming whether the ledge 66 of the first block 40a is engaging in the hole 94 or not.

According to the present embodiment, furthermore, the opening 107 isdisposed in facing relation to the connector support 100. When theattachment structure 12 is molded using the die assembly 120, a portionof the attachment structure 12 which is lower than the lower end 108 ofthe hook 104 is molded by the lower die 124, whereas at least a portionof the attachment structure 12 which is higher than the lower end 108 ismolded by the upper die 122. Since the lower die 124 has the extension126 extending through the opening 107 to the connector support 100,after the attachment structure 12 is molded using the die assembly 120,the lower die 124 is slid in the direction indicated by the arrow B2.Therefore, the lower die 124 can easily be removed. When the upper die122 is removed in the direction indicated by the arrow C1, theattachment structure 12 molded to desired shape is obtained.

According to the present embodiment, the light source support 92 and thewall 102 are positionally displaced in the directions indicated by thearrow A, thereby defining the opening 107, so that the connector support100 with the hook 104, and the light source support 92 and the wall 102do not face each other. Therefore, the upper die 122 and the lower die124 which jointly make up the die assembly 120 are prevented from beingcomplex and wasteful in structure.

In the above description, the opening 107 is disposed in facing relationto the connector support 100. However, another opening may be providedin facing relation to the light source support 92, and the lower die 124may have another extension extending through the other opening to thelight source support 92. Such a modification offers the same advantagesas those described above.

The illumination hole 26, the hole 94, and the opening 107 arepositionally displaced from each other, thereby preventing theattachment structure 12 from being reduced in rigidity at one locationdue to openings.

The illumination hole 26 is defined outwardly from the light unit 44 inthe outward direction of the vehicle, i.e., in the direction indicatedby the arrow B2 away from the occupants of the vehicle, so that thelength of the illumination hole 26 along the directions indicated by thearrow A can be increased in the outward direction of the vehicle awayfrom the occupants of the vehicle.

According to the present embodiment, moreover, the attachment structure12 and the upper surface 24 of the door pocket 18 of the door lining 14as an attachment target are integral with each other. Therefore, theprocess of installing the lighting device 10 on the upper surface 24 iscompleted by placing the lighting device 10 on the rest 80 of theattachment structure 12 and supporting and fixing the lighting device 10with the walls 90, 102, the light source support 92, the hole 94, therecess 96, the connector support 100, and the hook 104. As a result, thenumber of parts used and the number of man-hours for installing thelighting device 10 are reduced compared with the background art, makingit possible to install the lighting device 10 on the upper surface 24with a simpler arrangement. The rigidity of the attachment structure 12is increased as the attachment structure 12 and the upper surface 24 areintegral with each other.

Specifically, according to the present embodiment, compared with thesituation where the lighting device 10 is fixed to a member other thanthe door lining 14 and the other member is fixed to the door lining 14by screws or the like, the attachment structure 12 is integrally formedwith the door pocket 18, and the lighting device 10 is directlyinstalled on the upper surface 24 of the door pocket 18 by theattachment structure 12. Therefore, the installing process is madesimple and easy, and the mechanical strength of the attachment structure12 is increased.

According to the present embodiment, the rest 80 functions as anattachment angle changer for adjusting the attachment angle at which thelighting device 10 is installed on the upper surface 24. By adjustingthe attachment angle, it is possible to set the illumination angle ofthe illumination light 28 output from the lighting device 10 to adesired angle.

The rest 80 also functions as a height adjuster for keeping theplacement surface for the lighting device 10 substantially horizontal.The attachment angle can easily be changed by adjusting the height ofthe rest 80 depending on the state of the upper surface 24. As a result,while the illumination angle of the illumination light 28 output fromthe lighting device 10 is set to a desired angle, it is possible toinstall the lighting device 10 on the placement surface of the rest 80which is kept substantially horizontal.

On the rest 80, the ribs 82 rising from the upper surface 24 function asa height adjuster. As the ribs 82 are integral with the upper surface24, the number of parts used is reduced, and at the same time therigidity of the attachment structure 12 is increased.

At least one of the ribs 82 is joined to each of the walls 90, 102, thelight source support 92, and the connector support 100 as the mountingmembers. The rigidity of these mounting members can be increased whilethe illumination angle of the illumination light 28 output from thelighting device 10 is set to a desired angle.

According to the present embodiment, the ribs 98 joined to the lightsource support 92 support the light source support 92, the ribs 105joined to the connector support 100 support the connector support 100,and the rib 106 joined to the wall 102 supports the wall 102. Theoverall rigidity of the attachment structure 12 is thus increased.

According to the present embodiment, furthermore, the lighting device 10and the attachment structure 12, and the mounts 32 are staggered inmutually different positions along the directions indicated by the arrowA and disposed on the door lining 14. When the door arm rest 16 isremoved from the door lining 14, the lighting device 10 and theattachment structure 12 are prevented from getting in the way.

The present invention is not limited to the above embodiment, but mayemploy various arrangements without departing from the scope of theinvention.

1. An attachment structure for installing a lighting device on an attachment target, comprising: a bottom surface having a hole formed therein, the hole formed in the bottom surface of the attachment structure being configured for letting light from the lighting device pass through the hole; and a plurality of ribs formed around the hole, wherein the attachment structure has a shorter side and a longer side, four or more of the plurality of ribs are positioned adjacently to the hole, among the four or more ribs positioned adjacently to the hole, two ribs are arranged in parallel to one another at one end of the hole in a direction along the shorter side, and another two ribs are arranged in parallel to one another at another end in the direction along the shorter side, and each rib of the two ribs define a line with respective one of the another two ribs, wherein the line extends across the hole.
 2. The attachment structure according to claim 1, wherein the plurality of ribs extend in a direction along the shorter side of the attachment structure.
 3. The attachment structure according to claim 2, wherein a length of the at least one of the plurality of ribs positioned adjacently to the hole is smaller than a length of another one of the plurality of ribs that is positioned away from the hole.
 4. The attachment structure according to claim 3, further comprising a wall and a wall-shaped light source support that support side surfaces of the lighting device, wherein said wall and said wall-shaped light source support are arranged upstanding from the bottom surface of the attachment structure; and the wall and the wall-shaped light source support are connected to each other.
 5. The attachment structure according to claim 4, wherein the wall is joined to the at least one of the plurality of ribs positioned adjacently to the hole.
 6. The attachment structure according to claim 4, wherein the wall-shaped light source support is joined to the at least one of the plurality of ribs positioned adjacently to the hole and to the another one of the plurality of ribs that is positioned away from the hole.
 7. The attachment structure according to claim 4, further comprising: a wall-shaped connector support supporting a connector of the lighting device; and another wall supporting a portion of the side surface of the lighting device, wherein the wall-shaped connector support and the another wall stand on the bottom surface of the attachment structure.
 8. The attachment structure according to claim 7, wherein the wall-shaped connector support is joined to the another one of the plurality of ribs that is positioned away from the hole.
 9. The attachment structure according to claim 7, wherein the another wall is joined to the other one of the plurality of ribs that is positioned away from the hole.
 10. The attachment structure according to claim 7, wherein the wall-shaped connector support is supported by a first supporting rib different from the plurality of ribs and extending from the wall-shaped connector support in a direction outward along the shorter side of the attachment structure, and the another wall is supported by a second supporting rib different from the plurality of ribs and extending from the another wall in a direction outward along the shorter side of the attachment structure. 